Container

ABSTRACT

A container according to ISO standards as a mobile workspace in civilian and military use comprising a cuboid metal frame of ISO corners and edge profiles connecting these ISO corners as well as thermally insulated side walls, ceiling and floor. The edge profiles are designed in two parts and the two partial profiles of an edge profile run parallel to one another and the intermediate space between the two profiles is filled completely by a thermally insulating material, with the side walls, ceiling and floor having a vacuum insulation layer.

BACKGROUND OF THE INVENTION

This invention relates to a container according to ISO standards,designed as a mobile work space for civilian and military use (shelter)

ISO containers with a cuboid metal structural frame comprising ISOcorners and edge profiles connecting these ISO corners, as well asthermally insulated side walls, ceiling and floor are known from DE 3719 301 C2, for example.

The construction of the structure for CSC-certified stackable containers(1:1 design, not expandable, e.g., DE 37 19 301 C2, and 1:2 and 1:3expandable designs, e.g., EP 0 682 156 B1) is obtained essentially fromthe stresses that occur in shipping and the vertical loads that occurwhen up to nine units are stacked (CSC: International Convention forSafe Containers). Point loads and area loads are specified for thecontainer bottom. The tare weight of the equipment to be mounted theremust be applied to the walls. Wall cutouts for doors (emergency exit)and for the power supply, air conditioning ducts and optionally thewater supply increase the structural complexity and the number of heatbridges.

The thermal insulation should not be at the expense of the interior sizeand/or increasing the empty weight of the container. Heat transfercoefficients of 0.55 to 0.75 W/(m²K) can be achieved easily withsandwich walls having shearing rigidity (sheet metal-polyurethane-sheetmetal) with thicknesses of 40 mm to 60 mm. With current designs, theopenings, edges and corners increase the k value of the entire containerto values substantially greater than 1 W/(m²K).

For civilian and military applications (mobile sanitation facilities andwork rooms such as field command posts and communications systems) foruse throughout the world, even under extreme climate conditions, thereis a need for reducing the technical complexity and economic costrequired for the power supply and [heating and] air conditioning.Transmission losses of the container, which is closed on all sides, mayconstitute 30% or more of the heating and cooling demand, except forapplications with an extremely high fresh air demand (operating rooms).

The problem of substantially improving the thermal insulation cannot besolved by thicker thermal insulation layers and not with the usualstructural designs.

DE 197 47 181 A1 discloses a refrigerated container or insulatedcontainer which includes thermally insulated side walls plus ceiling andfloor, each framed by bordering copings. The bordering copings aredesigned as hollow profiles and have a core of thermal insulationmaterial. By way of edge profiles designed in two parts, the side walls,ceiling and floor are fixedly joined together in the area of thebordering copings. One disadvantage of this container is the fact thatheat bridges created due to the use of the hollow profiles have anegative effect on the heat transfer coefficient value of the container.

EP 0 064712 A1 describes a refrigerated container having a continuousinsulation layer. The exterior side of the insulation is formed by asteel frame with upper and lower cross beams and exterior wall panels.Interior planking is provided on the inside of the refrigeratedcontainer.

SUMMARY OF THE INVENTION

An object of the present invention is to reduce the heat transfercoefficient of the entire container without any sacrifice in terms ofstructural rigidity and interior size.

This object has been achieved by providing that the intermediate spacebetween the two partial profiles is filled completely by a thermallyinsulating material and side walls, ceiling and floor have a vacuuminsulation layer.

The present invention links two approaches together to achieve thisobject:

-   -   Reducing the transmission component of undisturbed areas by        using vacuum insulation material which has a much lower thermal        conductivity than polyurethane or mineral wool, for example, to        compensate for the disadvantage of heat bridges, and    -   A two-part design of all edge profiles of the container (in the        form of two partial profiles running in parallel and thermally        separated from one another by thermal insulation material) for        all horizontal and perpendicular edges of the cuboid ISO        container. The intermediate space between the two partial        profiles is filled completely by a thermal insulation material.        This principle can also be applied similarly for all frames of        area openings such as doors and drop doors. The structure of the        container can thus be implemented largely without heat bridges.

The heat transfer coefficient of the container according to thisinvention can be brought into the range of 0.5 W/(m²K) by the measuresdescribed here without having to accept sacrifices in terms ofstructural rigidity or interior size. In particular, the inventivecontainer can be stacked several units high without restriction.

The definite reduction in the heat transfer coefficient to values around0.5 W/(m²K) in the case of a wall thickness comparable to that ofconventional thermally insulated containers reduces the requiredcapacity of the air conditioning system by the amount that results fromthe temperature difference between the interior and the environment andthe greater temperature difference (plus and minus) between theair-conditioned air circulating in the side wall ducts and ceilingducts. Heating of the container by radiant wall heat and/or floorheating thus becomes much more economical.

The inventive concept may be used for containers that are not expandable(1:1 design) as well as for expandable containers (1:2 design, 1:3design, e.g., using pull-out elements).

The inventive container is in compliance with the strength and rigidityvalues stipulated by ISO standards. It is suitable in particular forstacking (up to nine containers stacked one above the other) and itwithstands the stresses that occur (e.g., load due to crane vehicle) inshipping of the container, in which case the force is applied at the ISOcorners.

The vacuum insulation technology developed for terrestrial applicationsis known per se and is used in the present invention (e.g., DE 296 08385 U1); this translates into a reduction in the weight and volume ofthe insulation material and thus an increase in the useful volume at apredetermined heat transfer coefficient. A granular or fibrous fillermaterial together with a getter material, if necessary, and IRopacifiers is surrounded by a multilayer laminated film (metal foil andpolyethylene film). With a system pressure of less than 5 mbar, tightwelding of the films and a negligible permeation rate, a lifetime ofmore than 15 years is achieved at a thermal conductivity ofapproximately 0.004 W/(mK) according to the manufacturer's information.The size of the vacuum insulation sheets in the thickness range from 10mm to 30 mm can be adapted to the geometric requirements.

The vacuum insulation, which is sensitive to damage, is advantageouslyprotected toward the outside by the outer steel plate wall of thecontainer and is preferably protected toward the inside byplastic-laminated plywood boards, the thickness of which is dimensionedfor appropriate mounting of furnishings and/or to accommodate floorloads according to the use case of the container.

In an advantageous embodiment, in addition to an insulation layer of avacuum insulation material, an additional insulation layer oftraditional insulation materials (mineral wool, rock wool, Styropor,Styrodur, polyurethane, etc.), i.e., non-vacuum insulation materials,may also be provided toward the interior.

The edge profiles which run vertically and horizontally between two ISOcorners can absorb normal forces and bending forces and mayadvantageously be designed as two partial L-shaped profiles mergedtogether but also as two quarter circle profiles on the inside andoutside or as an expander quarter round profile and a partial profile onthe inside comprising a quadrilateral profile or a tube profile.

The outer sheet metal wall of a container surface, which contributestoward its shear strength, is advantageously welded to the outer partialprofile of an edge profile and the ISO corners.

The large-area interspaces between opposing edge profiles are coveredwith vacuum insulation sheets, small intermediate spaces are filled withfoam or with other conventional insulation materials tailored exactly tofit.

The intermediate spaces between two partial profiles of an edge profilemay also be filled with foam or with conventional insulation materialsaccurately tailored to fit. The recent development of a weldable steelplate-polyurethane sandwich may be of interest here both economicallyand from the standpoint of manufacturing technology.

With the small thickness of the walls and ceilings and the minor offsetof the wall surfaces at the ISO corners, they protrude into the interiorof the container. To reduce these heat bridges, these protrusions mustbe covered with a layer of thermal insulation material in the form of atrunk corner. Especially here but also on all thermally criticallocations, the thermal insulation is such that the dew point can neverbe reached anywhere on the inside surface.

One wall (side wall, ceiling or floor) of the container advantageouslycomprises the following layers from the inside to the outside:

-   -   outer metallic cover layer,    -   vacuum insulation layer,    -   additional insulation layer of a non-vacuum insulation material,    -   plywood layer,    -   inner metallic or plastic cover layer.

To reinforce the side wall, ceiling or floor, reinforcing profiles mayadvantageously also be provided, these profiles being in contact eitherwith the inner or outer metallic cover layer of a side wall, a ceilingor floor and separated from the other cover layer by a thermalinsulation intermediate layer. Since the reinforcing profiles formessentially unwanted heat bridges, a metallic material with a lowthermal conduction and a high strength may advantageously be selectedfor them.

To accommodate floor loads in spots and over the area, a compromise mustbe made for thermal reasons between thermal conduction, the crossprofile of the profile and the distance between the reinforcing profiles(grid dimension). In addition to the choice of the smallest possible webthickness of the standard profiles, it may also be expedient to usecomposite welded profiles, with stainless steel plate being advantageousthermally for the web(s), either straight or inclined, because of thelower heat transfer coefficient.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other objects, features and advantages of the presentinvention will become more readily apparent from the following detaileddescription of currently preferred configurations thereof when taken inconjunction with the accompanying drawings wherein:

FIG. 1 is a partial, cross-sectional view showing the wall design of thecontainer of the present invention with an L-shaped reinforcing profile;

FIG. 2 is a partial, cross-sectional view showing the wall design of thecontainer of the present invention with an assembled reinforcingprofile;

FIG. 3 is a partial, cross-sectional view through a container of thepresent invention in the area of an edge profile, where the edge profileconsists of two L-shaped partial profiles;

FIG. 4 is a partial, cross-sectional view through a container of thepresent invention where the edge profile includes a curved partialprofile on the outside and a partial profile of a pipe profile with webswelded onto it on the inside;

FIG. 5 is a partial, cross-sectional view through a container of thepresent invention with an edge profile consisting of two L-shapedpartial profiles; and

FIG. 6 is a partial, cross-sectional view through a container of thepresent invention in the area of a wall passage for a door or a dropdoor.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 shows the wall structure (side walls, floor or ceiling) ofcontainer constructed in accordance with the present invention.Beginning from the outside, the multilayer wall structure includes themetallic outside wall 1 (steel plate which is planar or trapezoidal), alayer of vacuum insulation sheets 2 cut to size and inserted and havinga thickness which depends on the requirement[s] regarding the quality ofthe heat transfer, the intermediate layer 3 of conventional insulationmaterials, e.g., mineral wool, a plywood 4 with a high E modulus toreinforce the wall for secure fastening of the interior furnishings ofthe container and finally the aluminum cover layer 5 which is to beglued onto the wooden board before assembly.

The total wall thickness is obtained from the wall stiffnessrequirements which are to be met with the lowest possible web thicknessof the reinforcing profile 6 and the greatest possible web length (fordefinition of a web of a reinforcing profile). Between the L-shapedreinforcing profile 6 and the plywood board 4 a strip 7 of thermalinsulation material is inserted. In the present case the reinforcingprofile 6 is welded to the metal exterior wall 1 and the wooden boards 4are attached by a rivet joint 8.

A variant of the reinforcing profile 6 is shown in FIG. 2 and consistsof selecting stainless steel as the material for the web 6′ (i.e., theregion of the profile 6 which runs across the layer structure and thusin the direction of heat conduction) for reasons of lower heatconduction and to weld it to the belt 6″ while otherwise having the samestructure. In FIG. 2 the reinforcing profile is designed in a T shape.

The path of the heat conduction may also be extended by placing the web6′ at an inclination. A symmetrical arrangement of two webs 6′ perprofile is expedient (symmetrical to a plane of symmetry perpendicularto the wall of the container), so that the webs 6′, belt 6″ and exteriorwall 1 form a trapezoid. The resulting hollow space can be filled outwith foam.

FIG. 3 shows a vertical cross section through a container, with part ofa side wall and the bottom or floor being shown here. The side wall andbottom have the sequence of layers according to FIG. 1 or FIG. 2: namelyexterior cover metal plate 1, vacuum insulation layer 2, insulationlayer of traditional insulation material 3, plywood board 4, 4′,interior metal cover layer 5. It can be seen here that within thebottom, the plywood layer 4′ is slightly thicker than in the case of thecorresponding plywood layer 4 in the side wall and the roof (the roofnot being shown in FIG. 3). The edge profile of the container is formedfrom two L-shaped partial profiles 10 and 11 placed one inside theother, welded together at their end faces with ISO corners (one ISOcorner 13 is visible in this sectional drawing). The outer cover plates1 are welded at points 1′ and 1″ to the profile legs of the outerpartial profile 10. The intermediate space between the interior andexterior profiles 10, 11 is filled with insulation material 40, insertedafter the welding operation or foamed in place. The entire intermediatespace between the profiles 10, 11 is thus filled homogeneously by theinsulation material 40 so there are no heat bridges. In particular thereare no other beam profiles (in contrast with the abovementioned DE 19747 181 A1, for example) between the two partial profiles 10, 11.Preferably a non-vacuum insulation material is used as the insulationmaterial. The cover angle 14 preferably made of plastic covers the seambetween the floor and the side wall.

If a greater rigidity is necessary for the horizontal container edgesaround the bottom, then according to FIG. 4 the interior partial profilemay have a greater cross section, e.g., may be designed as a hollowprofile member such as a tube or pipe 20 with tabs 21, 22 welded on forfastening the interior covers 4 and 5 and/or 4′ and 5′. The exteriorpartial profile of the two-part edge profile is designed as an arc of acircle 23 in this embodiment.

FIG. 5 shows a horizontal cross section through a container in the areaof a vertical container wall. The two abutting side walls designedaccording to FIG. 1 and FIG. 2 can be seen here. The two-part edgeprofile again consists of the two L-shaped partial profiles 10, 11 whoseend faces are welded to a surface of the ISO corner 31. If the leglengths of conventional L profiles cannot be coordinated with theirdistance so that there is no offset in the joints 25, 26 in relation tothe walls 27, 28, this does not constitute in principle a structuralchange in the wall design. The three-layer lining 30, e.g., a foamedsurface compacted plastic, covers the areas of the ISO corners 31protruding into the interior of the container to diminish the effect ofthe heat bridge formed by the ISO corner.

FIG. 6 shows one interrupted embodiment of a wall opening for a door ordrop door. The layer structure of the wall 40 and of the door or dropdoor 41 is identical. The layer structure depicted here has only aninsulation layer consisting of a vacuum insulation material in contrastwith the embodiments depicted in the previous figures. The opening isbordered on the side of the drop door as well as on the wall side byceiling panels 42, 43 and/or 44, 45 in two parts. The intermediatethermal insulation layers 46, 47 between the ceiling panels 42, 43and/or 44, 45 prevent the transfer of heat. The element 48 provides theseal around the frame. The hinges 49 are mounted on the outside of thecontainer.

1. Container according to ISO standards as a mobile workroom, comprisinga cuboid metal frame of ISO corners and edge profiles connecting the ISOcorners, thermally insulated side walls, ceiling and floor, wherein theedge profiles are comprised of outer and inner parallel partial profilesand a thermal insulating material arranged in an intermediate spacebetween the outer and inner partial profiles, the side walls, ceilingand floor have an associated vacuum insulation layer, and each of theouter partial profiles is butt-welded to a cover plate associated withan adjoining side wall to form a planar surface.
 2. Container accordingto claim 1, wherein the two-part edge profiles are L-shaped partialprofiles placed one inside the other as two partial quarter-roundprofiles on the inside and on the outside or as an exterior partialquarter-round profile on the outside and on the inside a hollow profilemember having tabs welded on two sides.
 3. Container as claimed in claim2, wherein the hollow profile member has a tubular shape.
 4. Containeras claimed in claim 1, wherein a side wall, ceiling or floor eachcomprises from the outside thereof to the inside thereof an exteriormetal cover layer, a vacuum insulation layer, an insulation layer of anon-vacuum insulation material, a plywood layer, and an interior metalor plastic cover layer.
 5. A container as claimed in claim 4, thetwo-part edge profiles are L-shaped partial profiles placed one insidethe other as two partial quarter-round profiles on the inside and on theoutside or as an exterior partial quarter-round profile on the outsideand on the inside a hollow profile member having tabs welded on twosides.
 6. Container as claimed in claim 5, wherein the hollow profilemember has a tubular shape.
 7. Container as claimed in claim 4, whereinreinforcing profiles are provided for reinforcing the side wall, ceilingor floor, and are in contact either with the interior metal cover layeror the exterior metal cover layer of the side wall, ceiling or floor andare separated from the other cover layer by an intermediate layer ofthermal insulation.
 8. Container as claimed in claim 7, where a web of areinforcing profile of the container surfaces consists of a metalmaterial, having a low thermal conductivity.
 9. Container as claimed inclaim 8, wherein the metal material is stainless steel.
 10. Container asclaimed in claim 1, wherein the areas of the ISO corners which protrudeinto the container interior are covered with a thermally insulatingmaterial.
 11. Container as claimed in claim 1, wherein the container hasopenings for doors or drop doors on the side wall, bottom or ceiling,with the frame for the openings and/or drop doors being thin-walled andmade of a metal material having a low thermal conduction, and withpartial profiles of the frame which are in contact with the inside oroutside of the container being separated by a thermally insulatinglayer.